Gas control and operation method of a fuel cell system for water and gas distribution

ABSTRACT

A gas control and operation method of a fuel cell system for improved water and gas distribution is disclosed. The present invention provides for a mechanization of a fuel cell system that allows control of the anode reactant and anode effluent through the anode portions of the fuel cell system to improve water and gas distribution on the anode side of the fuel cells that increases the voltage stability of the fuel cells.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.10/612,380, now U.S. Pat. No. 7,479,336 filed on Jul. 2, 2003. Theentire disclosure of the above application is incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates generally to fuel cell systems and moreparticularly to gas control and operation method of a fuel cell systemfor improved water and gas distribution.

BACKGROUND OF THE INVENTION

H₂—O₂(air) fuel cells are well known in the art and have been proposedas a power source for many applications. There are several types ofH₂—O₂ fuel cells including acid-type, alkaline-type,molten-carbonate-type, and solid-oxide-type. So called PEM (protonexchange membrane) fuel cells (a.k.a. SPE (solid polymer electrolyte)fuel cells) are of the acid-type, potentially have high power and lowweight, and accordingly are desirable for mobile applications (e.g.,electric vehicles). PEM fuel cells are well known in the art, andinclude a “membrane electrode assembly” (a.k.a. MEA) comprising a thin,proton transmissive, solid polymer membrane-electrolyte having an anodeon one of its faces and a cathode on the opposite face. The MEA issandwiched between a pair of electrically conductive elements which (1)serve as current collectors for the anode and cathode, and (2) containappropriate channels and/or openings therein for distributing the fuelcell's gaseous reactants over the surfaces of the respective anode andcathode catalysts. A plurality of individual cells are commonly bundledtogether to form a PEM fuel cell stack.

In PEM fuel cells hydrogen is the anode reactant (i.e., fuel) and oxygenis the cathode reactant (i.e., oxidant). Accordingly, the anode side ofthe fuel cell stack is supplied with hydrogen or a gas containinghydrogen and the cathode side is supplied with air. During theconversion of the anode reactant and cathode reactant to electricalenergy, the fuel cell produces anode and cathode effluents. The anodeside is typically operated in a “dead head” mode wherein the anodeaffluent is not continuously exhausted from the fuel cell stack. Withthis type of operation, nitrogen accumulates in the anode side of thefuel cells as a result of the diffusion through the MEA. Additionally,water also accumulates in the anode side. The accumulation of water andnitrogen results in a reduction in the operational level of the fuelcells and the voltage stability of the individual fuel cells of the fuelcell stack. This accumulation is typically concentrated in localizedportions of the anode side of the fuel cells and, as a result, can causethe reduction in the operational level and the voltage stability of thefuel cells to occur quickly. This localized accumulation causes thereduction in the operational level and the voltage stability of the fuelcell before the remaining portion of the fuel cell is affected.

In order to reduce the nitrogen and water accumulations in the anodeside, the anode side is flushed with anode reactant while the anodeeffluent is being vented from the anode side. However, the flushing ofthe anode side with the anode reactant leads to an anode effluent thatcontains a large quantity of hydrogen and therethrough leads to a higherhydrogen consumption. Thus, there is a need to address the accumulationsituation.

SUMMARY OF THE INVENTION

The present invention provides a gas control and operation method of thefuel cell system that addresses the accumulation situation, statedabove. Specifically, the present invention provides for a mechanizationof a fuel cell system that allows control of the anode reactant andanode effluent through the anode portions of the fuel cell system toimprove water and gas distribution on the anode side of the fuel cellsthat increases the voltage stability of the fuel cells and may result ina reduction of the quantity or frequency of a purging operation.

A fuel cell system according to the principles of the present inventionincludes at least one cathode section having an inlet and an outlet.There are at least two anode sections each having an inlet and outlet.The at least one cathode section and the at least two anode sections areoperable to convert an oxidant-containing cathode reactant in the atleast one cathode section and a hydrogen-containing anode reactant inthe at least two anode sections into electricity, an oxidant-containingcathode effluent and a hydrogen-containing anode effluent. A first flowpath is operable to supply a first hydrogen-containing anode reactantfeed stream to an inlet of a first anode section of the at least twoanode sections. A second flow path is operable to supply a secondhydrogen-containing anode reactant feed stream to an inlet of a secondanode section of the at least two anode sections. A first valve in thefirst flow path is operable to modulate flow through the first flow pathwhile a second valve in the second flow path is operable to modulateflow through the second flow path. There is a third flow path connectingan outlet of the first anode section to an outlet of the second anodesection so that the anode effluent from one of the anode sections canflow into an anode outlet of the other anode section. A third valvecommunicates with the third flow path and is operable to modulateventing of anode effluent from the third flow path.

A method of operating a fuel cell system having at least one cathodesection and at least two anode sections which are operable to convert anoxidant-containing cathode reactant and a hydrogen-containing anodereactant into electricity, a cathode effluent and an anode effluent isdisclosed. The method includes: (1) supplying a first anode reactantfeed stream to a first anode section of the at least two anode sections;(2) supplying a second anode reactant feed stream to a second anodesection of the at least two anode sections; (3) supplying an anodeeffluent from one of the first and second anode sections to the other ofthe first and second anode sections; and (4) adjusting a quantity of atleast one of the first and second anode reactant feed streams beingsupplied, so that alternatively, the one and then the other of the firstand second anode sections receives anode effluent.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a simplified schematic representation of a preferredembodiment of a fuel cell system according to the principles of thepresent invention;

FIG. 2 is a simplified schematic representation of a first alternatefuel cell system according to the principles of the present invention;

FIG. 3 is a graphical representation of a gas flow pattern for a fuelcell system according to the principles of the present inventionoperated with intermediate burping of the anode effluent;

FIG. 4 is a graphical representation of a gas flow pattern for a fuelcell system according to the principles of the present invention withcontinuous venting of anode effluent; and

FIG. 5 is a simplified schematic representation of a second alternatefuel cell system according to the principles of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following description of the preferred embodiment is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to FIG. 1, a preferred embodiment of a fuel cell system 20according to the principles of the present invention is shown. Fuel cellsystem 20 and its method of operation, as described below, provides forimproved water and nitrogen distribution throughout the anode sectionsof the fuel cell system and avoids the disadvantages stated above. Fuelcell system 20 includes first and second fuel cell stacks 22 and 24 thateach have a respective cathode side or portion 26 and 28 that eachreceive an oxidant-containing cathode reactant flow. First and secondfuel cell stacks 22 and 24 also each have a respective anode side orportion 30 and 32 that receive a hydrogen-containing anode reactant flowor fuel. Specifically, first anode side 30 of first fuel cell stack 22has an inlet portion 33 for receiving anode reactant flow and an outletportion 34 for discharging anode effluent produced therein. Likewise,second anode side 32 of second fuel stack 24 has an inlet portion 36 forreceiving the anode reactant flow and an outlet portion 37 fordischarging anode effluent produced therein. Each fuel cell stack 22 and24 is operable to convert the anode and cathode reactants intoelectricity, a hydrogen-containing anode effluent, and anoxygen-containing cathode effluent.

The hydrogen-containing anode reactant or fuel can be provided from avariety of sources. Such sources include, but are not limited to, areformate stream from a reformer and hydrogen from a hydrogen storagedevice. The cathode reactant can also be provided from a variety ofsources. Such sources include, but are not limited to, oxygen suppliedfrom an oxygen storage device and air drawn from the environment withinwhich fuel cell system 20 is employed. The cathode reactant supply tothe fuel cell stacks and the venting of cathode effluent produced in thefuel cell stacks will not be discussed in detail. It should beunderstood that cathode reactant will be supplied to the various fuelcell stacks in a quantity sufficient to meet the operational demands offuel cell system 20 and that cathode effluent will be removed from fuelcell system 20 as needed.

The anode reactant is supplied to fuel system 20 in a quantitysufficient to meet the operational demands of fuel cell system 20. Theanode reactant can be supplied to fuel system 20 in a variety of ways.For example, a gas injector (not shown) capable of metering a flowtherethrough can be utilized to inject anode reactant into fuel cellsystem 20. The anode reactant supplied to fuel cell system 20 is dividedinto first and second anode reactant streams 40 and 42 that flow to therespective anode inlet portions 33 and 36 of first and second fuel cellstacks 22 and 24 via first and second flow paths 44 and 46. First andsecond valves 48 and 50 are located in the respective first and secondflow paths 44 and 46. Valves 48 and 50 modulate the first and secondanode reactant streams 40 and 42 and, accordingly, control the divisionof the anode reactant supplied to fuel cell system 20. Specifically,valves 48 and 50 regulate the quantity of anode reactant flowing throughfirst and second flow paths 44 and 46 and, thus, the amount of anodereactant flowing to anode sides 30 and 32 of first and second fuel cellstacks 22 and 24. Valves 48 and 50 can divide the anode reactant flowingto fuel cell system 20 between flowing entirely to first fuel cell stack22 via first flow path 44 to flowing entirely to second fuel cell stack24 via second flow path 46 or a combination therebetween.

A third flow path 52 interconnects outlet portions 34 and 37 of therespective first and second anode sides 30 and 32. The interconnectionof outlet portions 34 and 37 enable anode effluent produced in one ofthe fuel cell stacks to flow into the anode side of the other fuel cellstack through the outlet on the other fuel cell stack, as describedbelow. A third valve 54 communicates with third flow path 52 and isoperable to modulate the venting of anode effluent from fuel cell system20. That is, third valve 54 is used to selectively vent anode effluentfrom fuel cell system 20, as described below. The anode effluent ventedfrom fuel cell system 20 via valve 54, depending upon the hydrogencontent, is either released to the atmosphere or sent to a downstreamcomponent (not shown). Valve 54 can be a simple open and closed valve ora proportional valve that is operable to regulate the quantity of anodeeffluent flowing therethrough. The operational requirements of thirdvalve 54 will vary depending upon how fuel cell system 20 is to beoperated, as described below.

A microprocessor or similar apparatus (not shown) is employed to controlthe operation of fuel cell system 20. The microprocessor controlsoperation of valves 48, 50 and 54. The microprocessor controls theindividual operation of the valves to operate fuel cell system 20 in adesired mode, as discussed below.

The arrangement of fuel cell system 20, illustrated in FIG. 1, utilizestwo separate fuel cell stacks 22 and 24. The gas control and operationmethod according to the principles of the present invention, however,can also be utilized with a fuel cell system 20′, illustrated in FIG. 2,that has a single fuel cell stack 60 having an anode side or portion 62that is partitioned or divided into two discreet anode sections 30′ and32′ that each receive an anode reactant stream, as described below.Single fuel cell stack 60 also has a cathode side or portion 64 thatreceives a cathode reactant stream, in the same manner as that disclosedabove for first and second fuel cell stacks 22 and 24. Accordingly, thecathode side 64 and the supplying of cathode reactant and removal ofcathode effluent will not be described further.

First anode section 30′ has respective inlet and outlet portions 33′ and34′. Similarly, second anode section 32′ also has respective inlet andoutlet portions 36′ and 37′. The anode reactant supplied to fuel cellsystem 20′ is divided between first and second anode sections 30′ and32′ as discussed above with reference to first cell system 20. That is,the fuel cell system 20′ also has first and second flow paths 44′ and46′ with respective valves 48′ and 50′ that are operable to divide anodereactant flowing to fuel cell system 20′ into first and second anodereactant streams 40′ and 42′. The outlet portions 34′ and 36′ ofrespective first and second anode sections 30′ and 32′ areinterconnected by a third flow path 52′. A third valve 54′ communicateswith third flow path 52′ to selectively vent anode effluent from fuelcell system 20′. Thus, the anode portions and the configuration tosupply anode reactant to the anode portions in fuel cell system 20′ issubstantially the same as that of fuel cell system 20. Due to thissimilarity, only the operation of the anode portions of fuel cell system20 will be described in detail. It should be appreciated, however, thatthe operation of the anode portions of fuel cell system 20′ aresubstantially identical to that of fuel system 20.

Fuel cell system 20 is operated to meet a known power load or demandplaced on fuel system 20. That is, a load or power requirement is placedon fuel cell system 20 and fuel cell system 20 is operated in a mannerappropriate to meet this load or demand. To meet the load placed on fuelcell system 20, the cathode reactant is provided to the cathode sides 26and 28 of first and second fuel cell stacks 22 and 24 in a quantitysufficient to meet the load. Similarly, anode reactant is supplied toanode portions 30 and 32 of first and second fuel cell stacks 22 and 24in a quantity sufficient to meet the load placed on fuel cell system 20.The cathode effluent is vented from first and second fuel cell stacks 22and 24 on an as needed basis with valves in cathode effluent flow pathsproviding regulation of the venting of cathode effluent and alsomaintaining a desired pressure within cathode sides 26 and 28 of firstand second first fuel cell stacks 22 and 24.

Anode effluent produced in anode sides 30 and 32 of first and secondfuel cell stacks 22 and 24 flows out of first and second fuel cellstacks 22 and 24 via the respective outlet portions 34 and 37. The anodeeffluent can be either vented from fuel cell system 20 via valve 54 orflow into the anode side of the other fuel cell stack depending upon theoperation of fuel cell system 20 and the flow rates of first and secondanode reactant streams 40 and 42, as discussed below. Venting of anodeeffluent from fuel cell system 20 can be performed in a variety ofmanners. For example, the venting of anode effluent can be through aburping operation, a discontinuous venting operation or a continuousventing operation, as described below. Preferably, anode effluent isvented from fuel cell system 20 in what is known as a burping operationor mode. The burping operation is characterized in that valve 54 isnormally closed and anode effluent is not being vented from fuel cellsystem 20 and a various times anode effluent is vented from fuel cellsystem 20 via valve 54 at a large rate for a short duration of time. Theburping operation also consists of increasing the supply of anodereactant flowing to first and/or second fuel cell stacks 22 and 24 whichprovides a large flow rate to purge nitrogen and water accumulated inthe anode sides 30 and/or 32 of first and/or second fuel cell stacks 22and 24.

Alternately, as stated above, anode effluent can be vented from fuelcell system 20 in a discontinuous manner. The discontinuous venting ofanode effluent is characterized by normally maintaining valve 54 closedwith anode effluent not being vented and at various times opening valve54 and venting anode effluent from fuel cell system 20 at a lower ratefor a longer duration of time relative to the burping operation. Thediscontinuous venting operation usually will require a slight increasein the flow rate of anode reactant to the first and/or second fuel cellstacks 22 and 24 through valves 48 and 50 in order to keep the anodepressure substantially constant. This increase is negligible in that itdoes not result in a significant differential pressure across the stacks22 and 24 or a higher turndown requirement for valves 48 and 50. Itshould be appreciated, that the lower rate of venting that occurs for alonger duration of time can provide an equivalent purging operation ofanode sides 30 and 32 of first and second fuel cell stacks 22 and 24 toremove nitrogen and water accumulated therein. Also alternatively, asstated above, anode effluent can be vented from fuel cell system 20 in acontinuous manner. A continuous venting of anode effluent ischaracterized by valve 54 being controlled to allow a continuous flow ofanode effluent to be vented from fuel cell system 20. These variousmethods of venting anode effluent from fuel cell system 20 are describedbelow in more detail with reference to operation of fuel cell system 20.

In the preferred operation of fuel cell system 20, anode reactant issupplied to fuel cell system 20 in a quantity sufficient to meet a loador demand placed on fuel cell system 20 and anode effluent is vented ina burping operation. The anode reactant is split into first and secondanode reactant streams 40 and 42 that flow through respective first andsecond flow paths 44 and 46. The partitioning of the anode reactant intofirst and second anode reactant steams 40 and 42 is performed by firstand second valves 48 and 50. Specifically, valves 48 and 50 are operatedto regulate the quantity of anode reactant flowing through first andsecond flow paths 44 and 46. First anode reactant stream 44 flows intoanode side 30 of first fuel cell stack 22 through inlet portion 33wherein the anode reactant is used to produce electrical power.Similarly, the second anode reactant stream 42 flows into anode side 32of second fuel cell stack 24 through inlet portion 36 wherein the anodereactant is used to produce electrical energy. At various intervals,valve 54 is opened and fuel cell system 20 is burped. When being burped,first and second anode reactant streams 40 and 42 exit the respectiveanode sides 30 and 32 through outlet portions 34 and 37 as anodeeffluent and are vented from fuel cell system 20 through third flow path52 and third valve 54. During the burping operation, valves 48 and/or 50are operated to increase the flow of anode reactant flowing to firstand/or second fuel cell stacks 22 and 24 to cause a large amount ofanode effluent to vent from fuel cell system 20 in a short duration oftime and facilitate the removal of nitrogen and water from anode sidesof first and/or second fuel cell stacks 22 and 24, as described below.

Anode effluent from first and second fuel cell stacks 22 and 24,however, is usually not being vented from fuel cell system 20 as thirdvalue 54 is usually closed and only opens during a burping operation. Inother words, valve 54 is only open at certain times during the operationof fuel cell system 20 and is closed during the other times. With thirdvalve 54 closed, anode effluent from first and second fuel cell stacks22 and 24 may or may not flow into third flow path 52. Rather, dependingupon the partitioning of the anode reactant flowing to first and secondfuel cell stacks 22 and 24, anode effluent produced in one of the fuelcell stacks may flow into the anode side of the other fuel cell stackthrough its outlet portion. That is, when first anode reactant stream 40is being introduced into first fuel cell stack 22 at a faster rate thansecond anode reactant stream 42 is being introduced into second fuelcell stack 24, the first anode reactant stream 40 will continue flowingthrough anode side 30 of first fuel cell stack 22 and exit via outletportion 33 into third flow path 52 as anode effluent. The anode effluentwill continue traveling through third flow path 52 until it encountersor meets second anode reactant stream 42 and/or anode effluent flowingout from second fuel cell stack 24 via outlet portion 37.

The location at which the two streams meet in fuel cell system 20 isconsidered a “dead spot” wherein flow through that location of fuel cellsystem 20 is essentially stagnant and a pressure balance of the twoflows occurs. The location of the stagnant or dead spot will varydepending upon the rate at which first and second anode reactant streams40 and 42 are introduced into fuel cell system 20 and can be moved byunbalancing the flows. For example, the dead spot can occur in the anodeside 32 of second fuel cell stack 24 when first anode reactant stream 40is being supplied at a faster rate than the second anode reactant stream42. In this case, anode effluent exiting the first fuel cell stack 22via outlet portion 34 will flow through the third flow path 52 and intoanode side 32 of second fuel cell stack 24 through outlet portion 37 onsecond fuel cell stack 24. Thus, the dead spot where the two flows meetoccurs in the anode side 32 of second fuel cell stack 24. Similarly, thedead spot can occur in anode side 30 of first fuel cell stack 22 whensecond anode reactant stream 42 is flowing into second fuel cell stack24 at a faster rate than first anode reactant stream 40 is flowing intofirst fuel cell stack 22. In this situation, anode effluent from secondfuel cell stack 24 flows through outlet portion 37, third flow path 52and into anode side 30 of first fuel cell stack 22 via outlet portion 34on first fuel cell stack 22. In an extreme case, either first or secondvalve 48 or 50 is closed while all the anode reactant is supplied tofuel cell system 20 via the open valve. In this situation, the anodereactant will flow through the first fuel cell stack that it encounters,exit that fuel cell stack as anode effluent and flow through the otherfuel cell stack in a reverse fashion entering through the outlet andexiting through the inlet of that fuel cell stack until it encountersthe closed valve. Thus, by controlling the rate at which first andsecond anode reactant streams 40 and 42 are allowed to enter fuel cellsystem 20, the location of the dead spot or stagnation of the anodereactant flows can be adjusted to occur at various locations throughoutthe anode flow paths of fuel cell system 20. Accordingly, it should beappreciated that the location of the dead spot can vary from being at anoutlet of one of the valves 48 and 50 or anywhere in between.

The ability to move the dead spot or point of stagnation of anodereactant throughout the anode flow paths of fuel cell system 20 allowsfor improved water and gas distribution throughout the anode portion.That is, the stagnation point is the location at which a significantamount of the nitrogen in the flow paths will accumulate. The ability todynamically move the location of the dead spot or point of stagnationthroughout the anode flow paths of fuel cell systems 20 causes thenitrogen and water in the anode flow paths to also move throughout theanode flow paths and be more evenly distributed along the membranesseparating the anode and cathode sides. The distributing of the nitrogenmore evenly along the surface of the membranes separating the anode andcathode sides increases the duration for which fuel cell system 20 canbe operated without venting anode effluent. That is, the more evendistribution of nitrogen along the surface of the membranes allows theperformance of all the fuel cells comprising the fuel cell stacks to beincreased and the performance of all the fuel cells will decrease at aslower and similar rate before decreasing to a point at which thenitrogen must be removed from the anode sides of fuel cell system 20. Byincreasing the intervals between venting of anode effluent, more of thehydrogen within the anode reactant streams 40 and 42 can be consumed toproduce electrical energy before being vented from fuel cell system 20as part of the anode effluent.

To achieve this better distribution, fuel system 20 is operated with thequantity of anode reactant supplied via first and second anode reactantstreams 40 and 42 dynamically varying relative to one another to movethe dead spot to different locations within the anode sides and flowpaths of fuel cell system 20. As the dead spot is moved about, thenitrogen and water in the anode sides and flow paths of fuel cell system20 will be more evenly distributed between first and second fuel stacks22 and 24. The adjusting or varying of the quantity of anode reactantsupplied via first and second anode reactant streams 40 and 42 can bebased upon a variety of control scenarios. One control scenario is basedon comparing the current operating condition of fuel cell system 20,such as load on the system, voltage stability of the fuel cells and/orfuel cell stacks, pressure, etc., to empirical data and based on thatcomparison adjusting the quantity of anode reactant supplied to firstand second anode reactant streams 40 and 42. The empirical data isestablished by operating fuel cell system 20 or an equivalent thereof ona test setup wherein the load on the fuel cell system is changed whileother operating parameters of the system are monitored, such as thenitrogen level, the nitrogen distribution, water level and waterdistribution, and cell voltages. The load on the fuel cell system iskept constant while the quantity of anode reactant supplied by the firstand second anode reactant streams 40 and 42 is varied. Based on theseobservations optimal adjusting quantities or times for adjusting thequantities are established that provide desirable operation of the fuelcell system, such as a substantially homogeneous distribution ofnitrogen and/or water throughout fuel cell system 20, increased voltagestability and a reduction in the amount of excess hydrogen vented fromfuel cell system 20. The load on the fuel cell system is then adjustedand the rates and/or intervals at which the quantity of anode reactantsupplied to fuel system 20 via first and second anode reactant streams40 and 42 is again varied to obtain optimal adjusting quantities and/ortimes for adjusting the quantities. The optimization can be based on avariety of factors, such as obtaining a desired nitrogen distribution,water distribution, and/or cell voltage output. However, it should beunderstood that other operating parameters can be monitored andoptimized in developing the empirical data and the associated adjustingquantities and/or time for adjusting the quantities.

A second control scenario on which operation of fuel cell system 20 canbe operated involves using an algorithm that determines the adjustingquantities and/or time for adjusting the quantities and then operating afuel cell system 20 based on the algorithm. The algorithm determines therate at which the quantities being supplied should vary and/or the timeat which the rates should be varied based on the load on fuel system 20or some other parameter, such as cell voltage. The algorithm chosen isbased upon providing a desired operation of fuel cell system 20, such asa desired nitrogen distribution, water distribution, and/or cell voltageoutput.

In a third control scenario, the anode reactant supplied via first andsecond anode reactant streams 40 and 42 is varied based uponpredetermined intervals and rates of changes. For example, as shown inFIG. 3, the quantity of anode reactant in first and second anodereactants 40 and 42 can be sinusoidal. That is, the quantity and/or flowrate of anode reactant in first anode reactant stream 40 can varysinusoidally, as represented by curve 70. Likewise, the quantity and/orflow rate of anode reactant in second anode reactant stream 42 can alsovary sinusoidally, as represented by curve 72. Curves 70 and 72 areshown as being 180° out of phase such that an average quantity or flowrate of anode reactant within fuel cell system 20 remains substantiallyconstant as represented by curve 74. Curve 74 is substantiallyhorizontal and indicates that the average quantity of anode reactant infuel cell system 20 is about a stoichometric flow rate of 1.0. Thesinusoidal variations of the quantity of anode reactant in first andsecond anode reactant streams 40 and 42 causes the dead spot within fuelcell system 20 to move and distributes the nitrogen and water moreevenly throughout fuel cell system 20. It should be appreciated that thefrequency of the sinusoidal curve(s) can be varied to achieve a desiredflow pattern and the variation can be based upon empirical data such asthat discussed above in relation to the first control scenario.

Anode effluent in fuel cell system 20, as stated above, is vented fromfuel cell system 20 in a burping operation. The burping operationinvolves opening the valve 54 so that a large quantity of anode effluentis vented from fuel cell system 20 over a short interval or duration oftime. Simultaneously, the quantity of anode reactant supplied to fuelcell system 20 via first and/or second anode reactant streams 40 and 42is substantially increased to force or purge the anode effluent alongwith the water and nitrogen from the anode flow path of fuel cell system20. The quantity of anode effluent vented from fuel cell system 20determines the amount of nitrogen and/or water that is purged from thefuel cell system. In other words, it is not necessary to purge theentire amount of water and/or nitrogen from fuel cell system 20 duringeach burping interval. The exact quantity of water and/or nitrogenpurged from fuel cell system 20 during the burping operation will varydepending upon the desired operation of fuel cell system 20.

The burping operation of fuel cell system 20 is illustrated in FIG. 3wherein curves 70, 72, and 74 experience spikes generally indicated as76. The spikes are indicative of the increased quantity of anodereactant supplied to fuel cell system 20 via first and second anodereactant streams 40 and 42 during the purging operation and theassociated increase in the average of these two flows. The period ortime interval between burping operations can vary, as discussed below.Additionally, the interval of the burping operations does not need to bein sync with the adjusting of the anode reactant flows. That is, asshown in FIG. 3, the burping operations are out of sync with thesinusoidal switching of the quantities of anode reactant supplied viafirst and second anode reactant streams 40 and 42. It should beappreciated, however, that the burping operation can be in sync with theswitching of the reactant flows, if desired.

The burping of anode effluent from fuel cell system 20 can be controlledsuch that only one fuel cell stack in fuel cell system 20 is purgedduring a given venting operation. That is, during the venting operation,only one of the valves 48 and 50 is adjusted to provide a surge of anodereactant to the associated downstream fuel cell stack while the othervalve allows a lower flow rate of anode reactant to the other fuel cellstack. The surge of anode reactant will flow through the associateddownstream fuel cell stack and exit the fuel cell stack as anodeeffluent that is then vented through valve 54. This surge of anodereactant helps purge the fuel cell stack through which it flows of waterand nitrogen. The other fuel cell stack receives anode reactant at arate sufficient to prevent the surge of anode reactant flowing throughthe fuel cell system from entering that fuel cell stack in a reversefashion. It should be appreciated, however, that a portion of the surgeof anode reactant may flow in a reverse fashion through the other fuelcell stack without departing from the scope of the present invention.The other fuel cell stack can then be purged through a subsequentventing operation by supplying a surge of anode reactant to that fuelcell stack while maintaining the other fuel cell stack with a flow ratesufficient to prevent or minimize the flow of anode fluid in a reversefashion through the other fuel cell stack. If desired, both fuel cellstacks can be purged simultaneously by increasing the flow of anodereactant to both of the fuel cell stacks while valve 54 is open. Thus,during a venting operation of fuel cell system 20, a single fuel cellstack can be purged of water and nitrogen or both fuel cell stacks canbe purged of water and nitrogen, as desired.

The interval between burping operations may vary and can be based upon avariety of control scenarios. Once control scenario can be based uponcomparing the current operating condition of fuel cell system 20 toempirical data and based on that comparison adjusting the time intervalbetween burping operations. The empirical data can be established inconjunction with the method described above with obtaining empiricaldata for the adjusting of the quantities and time between adjustments ofthe quantities of anode reactant flowing to the fuel cell stacks.

A second scenario for the burping of fuel cell system 20 is using analgorithm that determines burping times and then burping fuel cellsystem 20 based on the algorithm. The algorithm chosen is based uponproviding a desired operation of fuel cell system 20, such as a desirednitrogen distribution, water distribution, and/or voltage output.

In a third control scenario, the time at which fuel cell system 20 isburped is based upon a specific or multiple operating parameters of fuelcell system 20. That is, one or more operating parameters of fuel cellsystem 20, such as nitrogen level, water level, and cell voltagestability, is monitored and when a threshold for one or more of theseparameters is reached, anode effluent is vented from fuel cell system 20in a burping operation. If desired, the parameters monitored can bespecific to an individual fuel cell stack such that when the monitoredparameter for that fuel cell stack passes a predetermined threshold,that fuel cell stack is purged in a burping operation of fuel cellsystem 20 while the other fuel cell stack is not purged, as discussedabove. Thus, this control scenario facilitates the monitoring ofoperating parameters of the individual fuel cell stacks and the purgingof nitrogen and water from a specific fuel cell stack on an as neededbasis or interval.

Accordingly, fuel cell system 20 is preferably operated in a burpingmode with the quantities of anode reactant supplied to first and secondfuel cell stacks 22 and 24 via first and second anode reactant streams40 and 42 being varied so that a desired operation of fuel cell system20 is obtained. The fuel cell system 20 can be operated in this mannerto provide a desired nitrogen distribution, water distribution, and/orvoltage stability of fuel cell system 20.

Fuel cell system 20 can be operated in a first alternate operating modewherein anode effluent is vented in a discontinuous manner which isdifferent from that of the burping operation described above. That is,as stated above, the burping operation is distinguished from thediscontinuous operation by the rate and duration of the ventingoperation. Specifically, the burping operation involves venting a largequantity of anode effluent in a short duration of time while in adiscontinuous venting operation anode effluent is vented at a lower orslower rate for a longer duration of time. Additionally, the burpingoperation is accompanied by a surge in the quantity of anode reactantflowing to the fuel cell stacks while in the discontinuous venting thesurge in anode reactant flow is not required. That is, the discontinuousventing operation is not a purging of the anode flow paths of fuel cellsystem 20 as is done with the burping operation and, accordingly, doesnot require a surge in the quantity of anode reactant being supplied tofuel cell system 20 and, as stated above, will require at most a slightincrease in anode reactant flow in order to keep the anode pressuresubstantially constant. When operating fuel cell system 20 withdiscontinuous venting of anode effluent, valve 54 is opened at varioustime intervals and for various durations to allow venting of anodeeffluent from fuel cell system 20.

The interval between the discontinuous venting of anode effluent and theduration of the venting occurrence can vary and can be based upon avariety of control scenarios. For example, the interval betweendiscontinuous venting occurrences and duration can be based uponcomparing the current operating condition of fuel cell system 20 toempirical data, based on an algorithm, or based on specific operatingparameters of fuel cell system 20, such as voltage stability of one ormore fuel cells and/or stacks, in the same manner as that stated abovewith reference to burping fuel cell system 20. The discontinuous ventingof anode effluent from fuel cell system 20 is done in conjunction withthe varying of the quantities of anode reactant supplied to the fuelcell stacks in first and second anode reactant streams 40 and 42 toprovide a desired operation of fuel cell system 20, such as a desiredwater distribution, nitrogen distribution and/or voltage stability.

The discontinuous venting of anode effluent allows the flow of anodeeffluent from one of the fuel cell stacks to enter the anode side of theother fuel cell stack via its outlet, even during the venting of anodeeffluent. This is achieved by providing anode reactant to one of thefuel cell stacks at a greater rate than to the other fuel cell stack andat a greater rate than is being vented from fuel cell system 20. Thiscauses a portion of anode effluent produced by one of the fuel cellstacks to be vented from fuel cell system 20 while the remaining portionof the anode effluent from that fuel cell stack can flow into the anodeside of the other fuel cell stack and result in a dead spot in the otherfuel cell stack. With this capability, a dead spot can still occurwithin the anode flow paths during the venting of fuel cell system 20and that dead spot can be adjusted throughout the anode flow path offuel cell system 20 by varying the quantities of anode reactant suppliedto first and second anode reactant streams 40 and 42 and the quantity ofanode effluent being vented from fuel cell system 20 which alters thepressure balance of the flows. Thus, fuel cell system 20 can be operatedwith a discontinuous venting of anode effluent and result in improveddistribution of water, nitrogen and/or voltage stability of fuel cellsystem 20.

Fuel cell system 20 can also be operated in a second alternate operatingmode wherein anode effluent is continuously vented from fuel cell system20. In this operating mode, valve 54 remains open and a flow of anodeeffluent is continually being vented from fuel cell system 20. Theamount of anode effluent being vented from fuel cell system 20 can varydepending upon the operation of valve 54. For example, valve 54 canprovide a very low and continuous rate of venting of anode effluent fromfuel cell system 20 or can be opened a further amount to allow anincreased flow of anode effluent from fuel cell system 20. During thecontinuous venting of anode effluent, the quantity of anode reactantsupplied to first and second anode reactant streams 40 and 42 will alsobe varied, as described above, to provide a desired operation of fuelcell system 20. Due to the continuous venting of anode effluent, thetotal quantity of anode reactant supplied to fuel cell system 20 ishigher than that when operated in the burping or discontinuous ventingmodes. For example, as shown in FIG. 4, the quantity of anode reactantsupplied to the first and second anode reactant streams 40 and 42 can bea gradual step change, as represented by curves 80 and 82 respectively.The average stoichiometric flow rate of anode reactant within fuel cellsystem 20, as indicated in curve 84, is above 1.0 due to the continuousventing of a portion of anode effluent from fuel cell system 20. Thestoichiometric rate at which anode reactant is consumed within fuel cellsystem 20, however, as indicated in curve 86, remains at 1.0 for theideal operation of fuel cell system 20.

The continuous venting of anode effluent still allows the flow of anodeeffluent from one of the fuel cell stacks to flow into the anode side ofthe other fuel cell stack via the outlet portion in a similar manner tothat discussed above. This is achieved by providing anode reactant toone of the fuel cell stacks at a greater rate than to the other fuelcell stack and at a greater rate than is being vented from fuel cellsystem 20. This causes a portion of anode effluent produced by one ofthe fuel cell stacks to be vented from fuel cell system 20 while theremaining portion of the anode effluent from that fuel cell stack canflow into the anode side of the other fuel cell stack and result in adead spot in the other fuel cell stack. With this capability, a deadspot can still occur within the anode sides and flow paths during acontinuous venting of anode effluent from fuel cell system 20 and thatdead spot can be adjusted throughout fuel cell system 20 by varying thequantities of anode reactant supplied to first and second anode reactantstreams 40 and 42 and the quantity of anode effluent being vented fromfuel cell system 20 which alters the pressure balance of the flows.Thus, fuel cell system 20 can be operated with a continuous venting ofanode effluent while improving the distribution of water, distributionof nitrogen and/or the voltage stability of fuel cell system 20. Itshould be appreciated, that if needed, valve 54 can be opened a largeramount so that a larger quantity of anode effluent can be vented fromfuel cell system 20 in a pseudo-purging operation as needed.

A second alternate embodiment of a fuel cell system according to theprinciples of the present invention is shown and indicated as 20″ inFIG. 5. Fuel cell system 20″ is substantially the same as fuel cellsystem 20, shown in FIG. 1, with the addition of a fourth flow path 100and a valve 102 that are used to provide a third anode reactant stream104. One end of fourth flow path 100 is connected to first and secondflow paths 44 and 46 upstream of first and second valves 48 and 50 whilean opposite end of fourth flow path 100 is connected to third flow path52. Valve 102 is positioned in flow path 100 between the first andsecond flow paths 44 and 46 and third flow path 52. With thisarrangement, anode reactant supplied to fuel cell system 20 can bepartitioned between first flow path 44, second flow path 46, and fourthflow path 100 to provide first, second, and third anode reactant streams40, 42, and 104. The addition of third anode reactant stream 104 to fuelcell system 20″ enables control of the concentration of anode reactantflowing into the outlets of the anode sides of first and second fuelcell stacks 22 and 24, as described below.

Fuel cell system 20″ is preferably operated with the anode effluentbeing vented in either a burping or discontinuous manner. The burping ordiscontinuous manner of venting anode effluent is chosen to preventthird anode reactant stream 104 or a portion thereof from being ventedfrom fuel cell system 20″ if operated with a continuous venting of anodeeffluent. That is, if fuel cell system 20″ is operated with continuousventing of anode effluent, at least a portion of the third anodereactant stream 104 would be directly vented and waste the hydrogencontained therein.

As stated above, third anode reactant stream 104 is used to control theconcentration of anode reactant flowing into the outlet of one of thefuel cell stacks. The addition of a third anode reactant stream 104 tothird flow path 54 enables fuel cell system 20″ to be operated in anumber of different manners that are not available with fuel cell system20 and 20′. A first operating mode involves using third anode reactantstream 104 to provide anode reactant to anode sides 30 and 32 ofrespective first and second fuel cell stacks 22 and 24 throughrespective outlet portions 34 and 37. In this operating mode, first,second, and fourth valves 48, 50, and 102 are operated to provide first,second, and third anode reactant streams 40, 42, and 104. Third anodereactant stream 104 will follow the path of least resistance (i.e.,either into anode side 30 through outlet portion 34, anode side 32through outlet portion 37, or be vented through third valve 54). First,second, and fourth valves 48, 50, and 102 are operated to provide aquantity of anode reactant in first, second, and third anode reactantstreams 40, 42, and 104 that causes dead spots to occur within bothanode sides 30 and 32 of first and second fuel cell stacks 22 and 24.Specifically, first anode reactant stream 40 flows into anode side 30 offirst fuel cell stack 22 via inlet portion 33 while a portion of thirdanode reactant stream 104 flows into anode side 30 of fuel cell stack 22via third flow path 52 and outlet portion 34. Simultaneously, secondanode reactant stream 42 flows into anode side 32 of second fuel cellstack 24 through inlet portion 36 while the other portion of third anodereactant stream 104 flows into anode side 32 of second fuel cell stack24 through third flow path 52 and outlet portion 37. The two portions ofthird anode reactant stream 104 will flow into the respective anodesides 30 and 32 of first and second fuel stacks 22 and 24 until theyencounter first and second anode reactant streams 40 and 42 and apressure balance of the flows occurs. This results in a dead spot orstagnation point within each anode side 30 and 32 of first and secondfuel cell stacks 22 and 24. The quantity of anode reactant supplied infirst, second, and third anode reactant streams 40, 42, and 104 can bevaried, as discussed above, to alter the pressure balance and move thedead spots around within the anode sides 30 and 32 of the respectivefuel cell stacks 22 and 24, to improve the water distribution, nitrogendistribution and/or voltage stability of fuel cell system 20″.

Alternately, fuel cell system 20″ can be operated in a second modewherein first, second and third anode reactant streams 40, 42, and 104are controlled to cause third anode reactant stream 104 to flow entirelyinto only one of anode sides 30 and 32 of first and second fuel cellstacks 22 and 24. For example, first valve 48 can be operated so thatfirst reactant stream 40 is of a quantity sufficient to flow entirelythrough anode side 30 of first fuel cell stack 22 and exit anode side 30as an anode effluent before encountering third anode reactant stream 104in third flow path 52 thus resulting in a dead spot within third flowpath 52. With the dead spot occurring in third flow path 52, third anodereactant stream 104 would flow into anode side 32 of second fuel cellstack 24 through outlet portion 37 and encounter second anode reactantstream 42 therein, thus resulting in a second dead spot occurring withinanode side 32 of second fuel cell stack 24. If desired, the rates offirst, second and third anode reactant streams 40, 42 and 104 can beadjusted so that the anode effluent exiting anode side 30 of first fuelcell stack 22 flows through third flow path 52 and joins with thirdanode reactant stream 104 and both the anode effluent and third reactantstream 104 flow into anode side 32 of second fuel cell stack 24 throughoutlet portion 37 and encounter second anode reactant stream 42 therein.This results in a single dead spot within anode side 32 of second fuelcell stack 24. The first, second and third anode reactant streams 40,42, and 104 can then be adjusted to alter the pressure balance and movethis single dead spot from anode side 32 of second fuel cell stack 24 toanode side 30 of first fuel cell stack 22. These capabilities of fuelcell system 20″ enable anode reactant to be supplied to an anode side ofa fuel cell stack through both its inlet and outlet. Thus, addition ofthird reactant stream 104 provides additional capabilities of providinganode reactants to the fuel cell stacks and of adjusting dead spotswithin the anode flow path of fuel cell system 20″ to improve the waterdistribution, nitrogen distribution and/or voltage stability.

The adjustment of the quantity of anode reactant in first, second, andthird anode reactants 40, 42, and 104 can be based upon a variety ofcontrol scenarios, as discussed above with reference to fuel cell system20 and 20′. That is, operation of fuel cell system 20″ can be based uponcomparing current operating conditions to empirical data, based upon analgorithm, and/or a specific operational parameter of fuel cell system20″. Thus, fuel cell system 20″ provides additional modes of operatingthe fuel cell system according to the principles of the presentinvention to improve the distribution of water, distribution of nitrogenand/or voltage stability of the fuel cell system.

Anode effluent, as stated above, is preferably vented from fuel cellsystem 20″ in either a burping or discontinuous mode. When the burpingor discontinuous venting occurs, it is preferred that fourth valve 102be closed so that there is no third anode reactant stream 104 flowinginto third flow path 52. By closing fourth valve 102, anode reactant isnot directly vented from fuel cell system 20″. The frequency of ventingand the duration of such venting of anode effluent when either in theburping or discontinuous mode, can be based upon the same controlscenarios and vary in the same way as discussed above with reference tofuel cell system 20.

While the present invention has been described with reference tospecific examples shown in the Figures and identified as fuel cellsystems 20, 20′ and 20″, it should be appreciated that variations can bemade in the configuration and operation of the various fuel cell systemswithout departing from the scope of the present invention. For example,one or more water separators (not shown) can be provided in third flowpath 52 to remove water from anode effluent flowing therethrough toprevent the addition of water into one of the anode sides 30 and 32through their respective outlet portions 34 and 37. Positioning of theseparator upstream of valve 54 will allow purging of liquid waterwithout purging gas at the same time. This would be beneficial forhydrogen efficiency in cases when a water purge is needed but a nitrogenpurge is not needed. Additionally, the varying of the anode reactant infirst, second and third anode reactant streams 40, 42 and 104 can varyfrom that shown in FIGS. 3 and 4. That is, the variation in these flowrates does not need to be sinusoidal, a gradual step change, or similarfunctions. Rather, the variations can be based upon different operatingscenarios, as discussed above, and can take a form that enablesoperation of the fuel cell system in a desired operational mode. Thevariation of the anode reactant streams, however, is preferred to begradual to avoid large pressure differentials between the anode andcathode sides of the fuel cell stack. Moreover, it should be appreciatedthat anode effluent can be vented from the fuel cell systems in a hybridventing operation wherein the venting of anode effluent can be in aburping mode, a discontinuous mode, a continuous mode, or a combinationthereof such that the venting of an anode effluent will change asoperation of the fuel cell system changes. Furthermore, it should beappreciated that while first, second and fourth valves 48, 50 and 102are shown as being used to regulate the quantity of anode reactantflowing therethrough, these valves can be replaced by gas injectors orsimilar devices capable of metering and regulating a quantity of anodereactant flowing therethrough.

The present invention alleviates the localized high concentrations ofnitrogen and water in the anode side of the fuel cells. Additionally, itleads to more even distribution of the nitrogen and water on the anodeside of the fuel cells to prolong the operation of the fuel cells beforerequiring a purging operation.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the gist of the invention areintended to be within the scope of the invention. Such variations arenot to be regarded as a departure from the spirit and scope of theinvention.

1. A method of operating a fuel cell system having at least one cathodesection and at least two anode sections which are operable to convert anoxidant-containing cathode reactant and a hydrogen-containing anodereactant into electricity, a cathode effluent and an anode effluent, themethod comprising: (a) supplying a first anode reactant feed stream to afirst anode section of the at least two anode sections through a firstflow path that communicates with a first inlet to the first anodesection; (b) supplying a second anode reactant feed stream to a secondanode section of the at least two anode sections through a second flowpath that communicates with a second inlet to the second anode section;(c) supplying an anode effluent from one of said first and second anodesections to the other of said first and second anode sections through athird flow path connecting a first outlet of the first anode section toa second outlet of the second anode section without passing through ananode section, the third flow path providing flow communication betweenthe first and second anode sections through the first and secondoutlets; and (d) adjusting a quantity of at least one of said first andsecond anode reactant feed streams being supplied, so that, alternately,the one and then the other of the first and second anode sectionsreceives the anode effluent.
 2. The method of claim 1, furthercomprising selectively venting anode effluent from the fuel cell system.3. The method of claim 2, wherein selectively venting anode effluentincludes continuously venting at least a portion of the anode effluentfrom the fuel cell system.
 4. The method of claim 2, wherein selectivelyventing anode effluent includes burping the fuel cell system.
 5. Themethod of claim 2, wherein selectively venting anode effluent includesdiscontinuously venting anode effluent.
 6. The method of claim 2,wherein selectively venting anode effluent includes regulating aquantity of anode effluent vented from the fuel cell system.
 7. Themethod of claim 1, wherein the adjusting includes varying the respectivequantities based on an operating parameter of the fuel cell system. 8.The method of claim 7, wherein the operating parameter is a voltagestability of at least one of the anode sections.
 9. The method of claim1, further comprising separating at least a portion of water containedin the anode effluent from the anode effluent of at least one of thefirst and second anode sections prior to supplying the anode effluent tothe other anode section.
 10. The method of claim 1, wherein theadjusting is based on one of empirical data and an algorithm.
 11. Themethod of claim 1, wherein the adjusting occurs at a predeterminedinterval.
 12. The method of claim 1, wherein the adjusting of the firstand second anode reactant feed streams achieves up to about 120% of ahydrogen stoichiometric requirement of the fuel cell system.
 13. Themethod of claim 1, further comprising supplying a third anode reactantfeed stream to the third flow path without the third anode reactant feedstream flowing through an anode section prior to reaching the third flowpath and wherein adjusting includes adjusting the quantity of at leastone of the first, second and third anode reactant feed streams.
 14. Themethod of claim 13, wherein the adjusting includes modulating the firstanode reactant feed stream flowing through the first flow path with afirst device, modulating the second anode reactant feed stream flowingthrough the second flow path with a second device, and modulating thethird anode reactant feed stream flowing into the third flow path with athird device.
 15. The method of claim 1, wherein all of the anodereactant flowing into the first inlet flows through the first flow path,all of the anode reactant flowing into the second inlet flows throughthe second flow path and wherein adjusting includes modulating the firstanode reactant feed stream flowing through the first flow path with afirst device that modulates all fluid flow through the first flow pathand modulating the second anode reactant feed stream flowing through thesecond flow path with a second device that modulates all fluid flowthrough the second flow path.
 16. A method of operating a fuel cellsystem having at least one cathode section and at least two anodesections which are operable to convert an oxidant-containing cathodereactant and a hydrogen-containing anode reactant into electricity, acathode effluent and an anode effluent, comprising: (a) supplying afirst anode reactant feed stream to a first anode section of the atleast two anode sections through a first flow path that communicateswith a first inlet to the first anode section; (b) supplying a secondanode reactant feed stream to a second anode section of the at least twoanode sections through a second flow path that communicates with asecond inlet to the second anode section; (c) supplying at least one of:(i) an anode effluent from one of said first and second anode sectionsto the other of said first and second anode sections and (ii) a thirdanode reactant feed stream through a third flow path connecting a firstoutlet of the first anode section to a second outlet of the second anodesection without passing through an anode section, the third flow pathproviding flow communication between the first and second anode sectionsthrough the first and second outlets; and (d) adjusting a quantity of atleast one of said first, second, and third anode reactant feed streamsbeing supplied with the proviso that, if the third anode reactant feedstream is not supplied through the third flow path then said adjustingcauses, alternately, the one and then the other of the first and secondanode sections to receive the anode effluent.